Interior package

ABSTRACT

In a preferred form the present invention relates to a contoured plastic sheet that is foldable into an open-sided box type configuration encompassing an article to be packed, the folded sheet and article therein adapted to be inserted as a unit into a box having substantially the same size interior dimensions as the external dimensions of the folded sheet. In this manner the article to be packed is effectively suspended within the outer box or container and is not subjected to direct shock load transmitted through the wall of the container.

United States Patent 72] Inventor Hazen J. Carroll Farmington, Mich.

[21 Appl. No. 773,892

'[22] Filed Nov. 6, 1968 [45] Patented Jan. 5, 1971 [73] Assignee Carroll Container Corporation Detroit, Mich. a corporation of Michigan [54] INTERIOR PACKAGE 2 Claims, 4 Drawing Figs.

[52] U.S. CI. 206/46, 2.Z 4 [51 1 Int. Cl 865d 85/30, 365d 25/12, B65d 5/50 [50] Field of Search 206/46FMC, 46Fragile; 229/2.5, 14C; 217/5 [56] References Cited UNITED STATES PATENTS 2,863,595 12/1958 Emery 229/2.5

3,136,413 6/1964 Hall 206/46 3,439,860 4/1969 Wienecke..lr. 206/46X FOREIGN PATENTS 1,244,647 7/1967 Germany. 229/14 Primary ExaminerTheron E. Condon Assistant Examiner-Neil Abrams Attorney-Barnard, McGIynn and Reising ABSTRACT: In a preferred form the present invention relates to a contoured plastic sheet that is foldable into an open-sided box type configuration encompassing an article to be packed, the folded sheet and article therein adapted to be inserted as a unit into a box having substantially the same size interior dimensions as the external dimensions of the folded sheet. In this manner the article to be packed is effectively suspended within the outer box or container and is not subjected to direct shock load transmitted through the wall of the container.

I PATENTEU'JAN 5 IBYI SHEET 2 [IF 2 INVENTOR. Hazen JCarz'ol/ M INTERIOR PACKAGE This invention relates to packaging devices and more particularly to an interior package formed of a cast plastic plate.

In the packaging of certain articles having an irregular outer surface, it is desirable to support the article within a package for shipment in a manner offering support to various irregular surfaces of the article. This is important so that the article does not rattle around in the box or container during shipment causing damage to the article by shock transmitted through the walls of the container at times without actually damaging the container. This problem comes into sharp focus in the packaging of articles that aredelicate from one standpoint or another; for example, appliances and more particularly an electric iron. An electric iron has a relativelystrong, flat support surface forming a sole made from material such as steel, but is joined with less sturdy sheet metal or plastic material immediately adjacent thereto, and finally a third element such as a handle is provided in which a control mechanism is housed. The composite iron has high shock resistance on a plane normal to the steel sole but is relatively fragile when shock is transmitted in any plane normal to the plastic parts.

The prior art is replete with devices intended to lower the shock transmittal from the outside of a compositepackage to an article packed within. Generally the art' teaches cardboard members that can be folded into many configurations but normally these configurations have angles or'apertures formed with cardboard and do not include contour shapes to accommodate the particular contour of an article. In addition, it is package is thereby prevented-Most outer containers are,

boxes that have walls at right angles to each other and, therefore, the problem becomes one of accommodating an irregularly shaped article to be packed in a square container.

It is an object of the present invention to provide an improved interior packaging device which-adapts itself to the contour of an irregularly shaped object .to be packed while forming a substantially square or oblong interior pack that is capable of being itself fitted into an exterior container with no relative movement allowed.

It is another object of the present invention to provide an improved interior package that is particularly adapted to be used with electric irons.

It is still another object of the present invention to provide an improved interior packaging device which is contoured so that an article to be packed is effectively separated from the exterior of the packaging device thereby diminishing shocks transmitted from the exterior to the article.

It is a further object of the present invention to provide an 5 improved method for packing an article in an interior package which assembly is later adapted to be placed into an outer box or container.

It is still a further object of the present inventionto provide an improved combination of an outer container, an inner package, and an article to be packed suspended within the inner package so that shocks transmitted to the exterior container are dampened before they act on the article to be packed inside the interior package.

"is yet a'further object of the present invention to provide an improved interior package which generally comprises a vacuum cast sheet of plastic that 'is controllably foldable around an object to be packed so that contours of the interior package mate with contours of the articlewith the outer walls of the interior package being substantially at right angles to adjacent outer walls adapting the assembly to be inserted into anouter packaging container.

Further objects and advantages of the present invention will be apparent from the following description, reference being had to the accompanying drawings wherein a preferred embodiment of the present invention is clearly shown.

, In the drawings: I

FIG. 1 is a sectional view of the subject invention with the article to be packed shown in outline form in the position it would assume inside the container.

FIG. 2 is a sectional view taken along line'2-2 of FIG. 1.

FIG. 3 is a perspective view of the subject invention shown in the form it assumes before being folded around the object to be packed.

FIG. 4 is a sectional view taken along lines 4-4 of FIG. 3 with the folded sheet shown in phantom.

Referring'to FIG. 3, a flat, integral sheet member 10 is shown as having a first surface 12 formed into an elongated contoured element and a second surface 14. The surface 14 is better seen in FIG. 4. The sheet member 10 has fold lines 16 18 and 20 integrally formed into said first surface at spaced intervals adapting said sheet member to be folded to form a four-walled envelope with each wall being perpendicular to each adjacent wall similar to the configuration in phantom shown in FIG. 4.

Referring to FIG. 3, first surface 12 of sheet member 10 has contoured areas 22, 24 .and 26 formed thereon, said contoured areas mating with substantially complementary shaped portions of the article to be packed when said sheet is folded into the configuration shown in phantom in FIG. 4 and in FIG. 1. In the example given, the article to be packed is an electric iron 21 and therefore areas 22, 24 and 26 mate with various 7 support surfaces of the iron. It is obvious that the shape of the contoured areas and the exact dimensions of sheet 10 depend on the article to be packed. An envelope is thereby formed around the article with substantially no relative movement being permitted the article and the sheet member with no part of the exterior surface of the article extending beyond the envelope in any plane. Contoured area 28 is adapted toengage 'the sides of the sole 29 of the iron with flat surface 30 receiving the flat portion 31 of the sole. The contour'32 is spaced from contoured areas 28 a sufficient amount so that when the leading edge of the sole contacts the edges of contoured area 28, the heel 33 of the sole plate will engage contour 32. Therefore, the iron is not movable with respect to sheet 10 once it is placed in its packed supported position.

Referring to FIG. 4, thesecond surface 14 is formed in complementary fashion with respect to said first surface and presents a plurality of support surfaces, for example, surfaces 34, 36, 38, 40, 42 and'44 and flat areas therebetween formed along planes perpendicular to each other once said sheet member is folded around the article to be packed. The plurality of support surfaces lends rigidity to the walls of said fourwalled envelope and iron disposed thereiri with fiat areas on said second surface being adapted to engage the inside surfaces of a container 46, seen in FIG.;1, so that there is substantially no relative movement between the iron when packed in the container, the contours 22, 24, and 26 acting to reducethe transmission of shock forces from the exterior of the container 46 to the iron when it is in its packed configuration.

Sheet 10 may be formed of any suitable plastic material having a thickness'in the range of .005 .of an inch to .060 of an inch. In the particular embodiment illustrated for packaging an iron, high impact polystyrene is employed having a thickness in the range of .010 of an inch to .020 of an inch, with a thickness of .012 of an inch being preferred.

Preformed sheet 10 may be fonned in any well-known manner, but is preferably yacuum cast to the elongated shape shown in FIG. 3 and in this form can be very readily stacked with other similar members taking up very little storage space. The contoured portions 22, 24 and 26 are elevated from the basic plane of the sheet so that the article is essentially suspended in the shipping container out of bearing contact with any wall thereof substantially as seen in FIG. 1.

Referring to FIG. 1, it is therefore seen that the present invention involves a container 46, and an interior packaging device comprising a contoured sheet member adapted to be folded into a package forming an exterior dimension to the inside dimension of the container 46, the contoured sheet member 10 suspending an iron 21 between contoured portions when folded into a package with no portion of the article coming into direct contact with the container 46. An examination of FIG. 1 indicates that the contoured sheet 10 and container 46 are so closely dimensioned that there is substantially no relative movement between them possible when they are in assembled disposition. It is also obvious that the contoured portions 24, 22 and 26 engage the nose, handle, and a rear block of the iron 21 in such a fashion as to effectively suspend the iron within the interior package, thereby providing a shock-absorbing means to lessen the effect of forces transmitted from the exterior of the box in container 46. Therefore, it can be said that the present invention teaches an envelope of substantial rectangular shape adapted to receive an electric iron with substantial registry of all exterior sides of the rectangular envelope with interior walls of the container 46 with the absence of registry of any support portion of the electric iron 21 with said container 46.

The flat plastic sheet disclosed herein adapts itself to a novel method of packing an article. For example, the integral preformed sheet 10 as seen in FIG. 3 can be placed on a work table. Next an article to be packed such as an iron would be placed in the area of the preform bounded by the contoured areas 28 and 32 which are exactly dimensioned to receive the contour of the base of the iron. Next a portion of the preform in which contoured area 26 is formed could be folded away from the work table toward the iron to engage the contour of the iron near the front thereof,- said folding being accomplished along fold line so that that portion of the preformed sheet would be disposed at right angles with respect to the flat surface 30. Next a second portion of the preform in which contoured area 24 is formed would be folded away from the work table along fold line 18 so as to engage the contour of the rear of the iron, thereby disposing such portion of the preform forming at a right angle with respect to the fiat area 30. The third portion of the sheet 10 carrying contoured area 22 is then folded along fold line 16 so as to be disposed at a right angle with respect to the areas of the sheet carrying contoured areas 24 and 26. Contoured area 22 would engage the top surface of the iron and thereby would be formed an envelope of substantially rectangular shape. Finally, the envelope now formed around the iron would beinserted into a box or container having essentially the same interior dimensions as the external dimensions of the envelope. Finally, the assembled iron interior packing container would assume the configuration shown in F IG. 1 wherein the packaging was complete.

Referring both to FIGS. 1 and 2 it is seen that the iron as disposed in the box or a container 46 can be held stationary therein in view of the close dimensioning between the outer periphery of the envelope and the box. Likewise, as shown in FIG. 2, the iron is suspended between contoured areas 28 and 32 in such a fashion that no relative lateral movement between the preform and the iron is possible with 'no outer area of the iron coming into direct contact with the container. Therefore, shock loads must be transmitted through the interior package or envelope formed from sheet 10 to act against the iron. Only sole 31 of the iron has any substantial bearing surface with sheet 10 and that is in area or flat surface 30. sole 3! normally being composed of a steel material which is very hard and not susceptible to shock damage.

An examination of the sheet in FIG. 3 illustrates the adaptability of the subject article and method to be performed with any variety of items besides an iron. Only one dimensioning in a die need be made originally, thereafter in an automated manner well-known in the art, sheet 10 can be vacuum cast into the desired dimension so that the contoured areas thereon are made with complementary shaped portions of the article to be packed to form the enclosure shown in phantom lines in FIG. .Thrs package is then rnsertable into an outer container with a maximum amount of shock resistance incorporated into the pack at a minimum of cost.

While the embodiment of the present invention, as herein disclosed, constitutes a preferred form, it is to be understood that other forms might be adopted.

Iclaim:

1. In a package for an electric iron having a flat pointed sole and a handle, a contoured plastic sheet insert to be placed between the iron and a rectangular container to isolate the iron from the container and comprising: a first flat surface portion for mating against said sole and having laterally opposite raised portions on one end thereof conforming to the pointed profile of the sole to prevent lateral displacement of the iron relative to the sheet insert, a second surface portion contiguous with said one end of the first surface portion and defined therefrom by a transverse fold groove, longitudinally extending peripheral ridges on said second surface portion and being beveled adjacent the fold groove to permit the second surface portion to be erected to a right angle relationship with the first surface portion, said second surface portion I also having a substantially raised central support configuration to mate with the front of the handle and having a longitudinally extending groove to cradle the handle therein, a third surface portion contiguous with the other end of said first surface portion and defined therefrom by means of a second transversely extending fold groove, longitudinally extending peripheral ridges on the third portion and being beveled adjacent the fold groove to permit the third surface portion to be erected to a right angle relationship with the first surface portion, a second substantially raised central support configuration on said third surface portion and mating with the rear of the handle, a fourth surface portion contiguous with an end of the third surface portion and defined therefrom by means of a transversely extending fold groove, longitudinally extending peripheral ridges on said fourth surface portion and being beveled adjacent the fold groove to permit the third and fourth surface portions to be placed in a right angle relationship, said fourth surface portion having asubstantially raised central support configuration to mate with the top of the handle and having a longitudinally extending groove to cradle the handle therein and prevent transverse displacement of the handle relative to the sheet insert, all of the raised support configurations being substantially hollow such that said sheet overall retains the character of a relatively thin-walled shell.

2. The apparatus defined in claim 1 wherein said sheet insert is of a thickness in the range between .010 inches and .020 inches. 

1. In a package for an electric iron having a flat pointed sole and a handle, a contoured plastic sheet insert to be placed between the iron and a rectangular container to isolate the iron from the container and comprising: a first flat surface portion for mating against said sole and having laterally opposite raised portions on one end thereof conforming to the pointed profile of the sole to prevent lateral displacement of the iron relative to the sheet insert, a second surface portion contiguous with said one end of the first surface portion and defined therefrom by a transverse fold groove, longitudinally extending peripheral ridges on said second surface portion and being beveled adjacent the fold groove to permit the second surface portion to be erected to a right angle relationship with the first surface portion, said second surface portion also having a substantially raised central support configuration to mate with the front of the handle and having a longitudinally extending groove to cradle the handle therein, a third surface portion contiguous with the other end of said first surface portion and defined therefrom by means of a second transversely extending fold groove, longitudinally extending peripheral ridges on the third portion and being beveled adjacent the fold groove to permit the third surface portion to be erected to a right angle relationship with the first surface portion, a second substantially raised central support configuration on said third surface portion and mating with the rear of the handle, a fourth surface portion contiguous with an end of the third surface portion and defined therefrom by means of a transversely extending fold groove, longitudinally extending peripheral ridges on said fourth surface portion and being beveled adjacent the fold groove to permit the third and fourth surface portions to be placed in a right angle relationship, said fourth surface portion having a substantially raised central support configuration to mate with the top of the handle and having a longitudinally extending groove to cradle the handle therein and prevent transverse displacement of the handle relative to the sheet insert, all of the raised support configurations being substantially hollow such that said sheet overall retains the character of a relatively thin-walled shell.
 2. The apparatus defined in claim 1 wherein said sheet insert is of a thickness in the range between .010 inches and .020 inches. 